Construction Revolution

Eco Underpass Method
Solution for Traffic Congestion in Urban Area

Introduction
Inspiration of Public Structure Appearance
Current Concept of Public Structures
Structures that are constructed for use in public are generally considered as “Permanent Structures” where themain emphasis is to build a strong and durable structure with higher factor of safety. These structures are mainly
reinforced concrete and expected to remain permanently, inflexible and bounded by three factors such as
purpose, location and function of structure. Recently, such permanent structures have been demolished as therequirements have been changed. Vast energy and time have been spent to destroy such strong and durable
structures and consequently, noise, vibration, exhaust gas and industrial waste are emitted. Considering theadvancement of science and technology, the concept of public structures has to be reviewed to accommodate
for the changing needs in accordance with cultural development

New Concept of Public Structures
If the concept of “Provision for Necessity” is fixed, satisfactory results cannot be achieved due to the fact thatimprovement in daily needs is a continuous process. Public facilities will be meaningless if they are not well
suited to the new requirements, which change according to the progress of science, technology and culturaldevelopment. Therefore, the current phrase of “Permanent Structure” has to be redefined to a new phrase called“Functional Structure”. Hence, “Functional Period” is the duration in which the structure is performing its function.
With this new concept for public structures, the construction methods and requirement of intended structures will
be totally different from before.

Design of Functional Structures
Functional Structures shall satisfy the current requirements and flexible enough to accommodate futureadjustments once the purpose, location and function of the structure are changed. Hence, it is important to caterfor this aspect during the design stage so that built structure can be easily removed once its functional needs
have to be changed. This is the basic concept of “Design of Functional Structures”. This concept also looks into
the re-cycling aspect of removable materials after the demolition of a structure. Hence, structures built for publicshould be designed based on function and not only on the strength itself, allowing full flexibility in accordance tocurrent and future requirements.

Construction Method for Functional Structures
Functional Structures shall satisfy the current and future requirements in accordance with changing social
demands. Thus, the construction method for functional structures shall be flexible during both construction andremoval stages. Most suitable construction materials shall be selected and installed by specialized machine sothat the future demolition works for the functional structures can be done easily and systematically. Hence, it isimportant to establish specialized method for each sequence of works.

1Eco Underpass Method

Life Cycle of Functional Structures

Construction

Start Functioning

Construction of Functional Structures basedon The Five Construction Principles

Perform Required Function

Construction Method
Development
Specialized Machines and Methods
based on New Concept

Functional Period
Design & Plan
Review of Function
Structural Design with Concerning
Future Removal & Demolition

Respond Flexibly to Required
Function Changes

RemovalRecycling
End of Functional Period due toCultural Development
Recovery of Natural Environment

Transfer & Re-use

Functional Structure to be transferred to other locations
Materials to be re-used2

General OutlineProblems in Urban Traffic
In the modern society, automobiles has spread remarkably, and its benefit to our daily life is immeasurable. On theother hand, traffic congestions become chronic and one of major causes environmental problems such as traffic
accidents, traffic noise and exhausted gas pollution. Despite of the high demand to immediately solve thoseproblems, they haven't been solved, yet. Especially in big cities, traffic congestions are so serious that they affect toenvironment, economy and securities. The major cause of the problems arises at busy road junctions.

Why are the problems not solved? – 3 Major Negative Factors
Generally, the busy road junctions are situated in the city centre. The degree of difficulty for construction works
in the area is high due to large passage of cars and pedestrians.
① Scarcity of Land
Land acquisition is difficult for new structures. There is not enough space for construction activities.
② Construction Period
Construction duration is usually too long to keep occupying existing traffics.
③ Construction Cost
Structure designs are complicated. Many work sequences are executed under restricted conditions.
No specialised construction method is established.

Conventional Structure and Method – Large Negative Factors Involved
Conventional structures are built with massive temporary reinforced concrete retaining wall. Hence, constructing
this type of structure will occupy large working spaces and necessitate many different sequences of works, andconsequently higher costs and longer construction period are inevitable. Nevertheless, no appropriate
construction machines and methods are available, yet. In urban area, construction of an underpass should not
rely on conventional methods, because there are too many negative aspects on the both structures andconstruction methods.

New Type of Structure and Method – Three Major Negative Factors Solved
Structures and construction methods Giken proposes are “Functional Structure” and “Eco Underpass Method”.
“Functional Structure” can dramatically change the duties and sense of value on conventional structures. “EcoUnderpass Method” is established for urban constructions based on the radically new idea. The basic concept ofthese ideas is derived from The Five Construction Principles; see p 13. It is capable of solving the 3 major
problems by the new structure and method.

Features of Functional Structures (Implant Structure)① The continuously pressed-in piles are employed as the both pile foundation and retaining walls for undergroundstructure. Those piles are embedded below the base slab level and form a stable structure by integrating theretaining walls and slab. This rigid structure can prevent the effect of liquefaction by earthquake.
② “Functional Structure” performs its function with full capability during the functional period. In case of any change
in the purpose of this structure, it is easily demolished and removed.
③ The structure is so simple that it requires the minimum land acquisition and construction materials are savedefficiently. It requires less temporary works and less energy consumption, thus it is cost effective.
④ The employment of a pre-tensioned girder enables the reduction in the thickness of overburden soil andreduces the required land space. Hence, the construction period can be reduced to minimize the effect tosurroundings.

3Eco Underpass Method

Features of Eco Underpass Method
Eco Underpass Method applies the GRB System which has the superiorities of the Press-in principle. It isestablished as an urban rehabilitation construction method for constructing underpasses.
① Solution to Land Space
systemized machineries can be small and compact, allowing works to be carried out under restricted working
space.
② Solution to Construction Period
scheduled completion can be achieved because of the systematic sequence of works. Earlier completion canbe achieved if multiple units are employed.
③ Solution to Construction Cost
structure can be constructed by simple press-in procedure at designated place, with emphasis on the “One-stepApproach” to eliminate temporary works. Less construction material and energy is required, enabling a shorter
construction period thus, reducing the construction cost.
④ Removal of Functional Structure
Structures that are for public use can be easily removed to accommodate the changes of purpose, location andfunction of structures, which will be considered during design stage. This method can be planned from thebeginning to construct the underpass in urban areas without causing obstruction to the existing traffic anddisruption to people and buildings.

This illustration is an example for a road junction. Other applications, such as crossing of railroads, approachpart of tunnels and underground structures are also available.

4Construction Method Comparison
Eco Underpass Method
The retaining wall is constructed using the GRB System where the whole piling operation walks along
and clamps onto previous installed piles, enabling the wall to be constructed with minimum disturbanceto the existing live traffic. Multiple units of machines can be mobilized on site to significantly reduce theconstruction duration and provide a total cost saving. Risk of collapse to the support system during
temporary works is eliminated considering the fact that the top slab is constructed before theexcavation work begins.

Press-in Piling in Progress

Workingn

Workingn

Excavation

Working Space

Working Space

Under Construction

RC Abutment

After Construction

Pre-tensioned Girder

RC Abutment

RC Base SlabContinuous Pressed-in Piles

5

RC Base SlabContinuous Pressed-in Piles

Eco Underpass Method

Conventional Method
Large working space is required using conventional piling equipments to construct the retaining wallsystem during the temporary stage. Bulky machine causes congestion on site, limiting the number ofmachines that could be mobilized at one time. Live traffic is disrupted, causing major inconvenient toroad users during the construction stage. Temporary decks are required to construct the permanentstructures.

Conventional Piling in Progress

Excavation

Under Construction

After Construction

Cover Plates

Strut

King Post
SMW Wall

RC Box Culvert

SMW Wall

RC Box Culvert

6Features of Method
Piled Raft Foundation
Multi-Functions; Pile Foundation and Spread Foundation
Under this design, the retaining wall has the both functions of the temporary wall and bearing superstructure.
After completion of the excavation work, the both sides of continuous pressed-in piles walls are connected withRC base slab. The extraction resistance force of the continuous piles will resist uplift forces due to high groundwater table. The structure is also stable against liquefaction by earthquake.

[ During Excavation ][ After Construction ]Pre-tensioned Girder (Use as Strut)

Pre-tensioned Girder (Use as Strut)

Cushioning Material

Cushioning Material
Buoyancy

Buoyancy

Pile Foundation

Pile Foundation

Skin Friction

Skin Friction

Continuous Pressed-in Piles

RC Base SlabContinuous Pressed-in Piles

Pile Foundation

Pile Foundation

Propped Function
Transfer Horizontal Force to Superstructure
The concept of this design is to transfer horizontal force to superstructures, the pre-tensioned girders. Thecushioning materials are inserted between the parapets of abutments and the both ends of the girders in order
to transfer not the bending moment but the horizontal force. In this design, the simple beam is applied, because
the fulcrums are at pile tops. As the result, stresses and deformations are smaller than those in cantilever beam,and no massive substructure is necessary.

[ Eco Under pass Method ][Conventional Method]( S imp l e Beam )( Cantilever Beam )HH
M

Bending Moment

Bending Moment

VM
VH

H

M

M

VV

H

HKv
KhKv
KhKh

Kh

Bending Moment

Bending Moment

Kv

Kv

Kv
H : Horizontal Force
V : Vertical Force
M : Bending Moment
Kv : Axial Spring
Kh : Lateral Spring

7Kv

Eco Underpass Method

Press-in Piling Using GRB System with the Minimum Space
Piling can be feasibly executed using the GRB System without reduction toexisting live lanes of road, resulting in less traffic congestion.

[During Press-in Piling]
Left Turn
Straight
FootpathRight Turn

Allowance

WorkingSpaceStraight

Allowance

Straight

Straight

WorkingSpaceFootpath

Continuous Pressed-in Piles

Safety Aspect
No Collapse of Road and Machine Stable
Construction of superstructure, such as pre-tensioned girders at level crossing extended part of slab structures,are completed prior to the commencement of excavation works. Road collapse, which is a common concern inconventional methods, is preventable. In addition, excavation work needs the only one layer temporary strutting.

[ Excavation for Cantilever Parts ]Temporary Struts

Last Excavation

RC Base SlabContinuous Pressed-in Piles

Implant Structure
Advantageous for Underground Lifelines
It is crucial to ensure that the construction is carried out without halting the life lines. To avoid the disruption oflifelines, space beside the road is necessary even during the construction works. The Giken wall system
requires less excavation and shoring works, thus minimizing the working space and allowing existing life lines tocarry on as per normal.

[ Eco Under pass Method ]Lifeline space[Conventional Method]

Implant Structure

Boundary

Boundary

Lifeline SpaceReverse T Type RC
Retaining Wall

Rainwater Drainage Pipe

Electricity CableTelecom Cable

Gas Pipe

Sewerage Pipe
Drinking Water Supply

Rainwater Drainage Pipe

Electricity Cable

Telecom Cable

Gas Pipe

Sewerage Pipe
Drinking Water Supply

8Work Sequence
STEP 1Press-in Piling Works at the Crossing Part[Multi-Unit Execution]
Left Turn
Straight

・ Press-in piling at the crossing part・ Construction of abutments at the crossing part・ Installation of cover plates at the crossing part

Footpath

Allowance

WorkingSpace

Right Turn

Straight

Straight

Allowance

Straight

WorkingSpace

Footpath

Continuous Pressed-in Piles

WorkingWorkin

Working
WorkinSTEP 2Press-in Piling Works at the Cantilever Parts・ Press-in piling by GRB System
・ Construction of cantilever slabs
・ Construction of footpath walls

Straight
Footpath

Straight

Allowance
WorkingSpaceStraight

WorkingSpaceAllowance

Left Turn
Straight

Footpath

Straight

Footpath

Straight
WorkingSpaceStraight

Right TurnWorkingSpaceAllowance

Footpath
Straight

Center Lanes
Continuous Press-in Piles

Continuous Press-in Piles

Working Space

Working Space

STEP 3

Installation of Pre-tensioned Girder at The Crossing Part[Multi-Unit Execution][One lane is closed at night time]

Left & Right Turns
Straight

WorkingSpace

Footpath

・ Excavation at the pre-tensioned girder area・ Installation of pre-tensioned girder・ Pavement WorkStraightFootpath

Pre-tensioned GirderWorking Space9Eco Underpass Methodg Spaceg SpaceLanes are closed during thepre-tensioned girder installation.

10Work Sequence
STEP 4

Excavation & Construction of the Base Slab・ Excavation & strutting works
・ Concrete placement for the base slab
・ Removal of strutting material

Straight
Footpath

Working
Space

Left Turn
Straight

Straight
Footpath

Straight

Footpath

WorkingSpace

Right Turn

Temporary Strutting
Temporary Strutting

Working Space

STEP 5Pavement & Miscellaneous Works

・ Road drainage construction・ Pavement & road markings
・ Construction of the electrical & pump room

Straight

WorkingSpace

Straight

Footpath

Footpath

Working Space

STEP 6

Pavement of the Side Roads & Miscellaneous Works[Activating Footpaths]
Side Road

Open Main Lanes

・ Drainage works at side walk・ Pavement & markings at side walk11

WorkingSpaceSide Road
Footpath

Footpath

Divider

Straight
Footpath

Straight

WorkingSpaceEco Underpass Method

1 23
Pump Room
Electrical Room

1 23
Pump Room
Electrical Room

12

Key Words
The Five Construction Principles
Even though construction industry has a tremendous influence to country, there is no definition for “Construction
Work” in the industry. At least public woks must be described in a manner that people can understand. For theanswer, “The Five Construction Principles” are the definitions, in accordance with public desire and the nature ofconstruction. They consist of 5 aspects, Environmental Protection, Safety, Speed, Economy and Aesthetic with anequilateral pentagon shaped symbol. If any one of these aspects is missing in a construction work, this work will
never be successful. If any one of them exceeds more than other aspects, this work will never be successful, either.
From now all construction methods and contractors should be selected based on the Five Construction Principles
rather than its size or history of the organisation and one’s connections.
Environmental
Protection

Construction work should be environmentally friendly and freefrom pollution.

SafetyConstruction work has to be carried out in safety and comfort witha method implementing the highest safety criteria.

SpeedConstruction work should be completed in the shortest possible
period of time.

EconomyConstruction work must be done rationally with an inventive mind
to overcome all constraints at the lowest cost.

Aesthetics

Construction work must proceed smoothly and the finished productshould portray cultural and artistic flavour.

Implant Structure
In order to support and fix structure, a base part is constructed at the bottom of the structure. The base part iscalled “Footing” which unifies with the Earth and the structure. The Implant Structure is a structure unifies with theEarth without footing. This structure has advantages, which can eliminate negative aspects of conventionalstructures. It is a perfect model, which satisfies the Five Construction Principles. It can minimise working space andeliminate temporary works and some work procedures. Implant Structure can be removed easily after the end of its
function or life cycle. It is substantial as ideal construction by the superiorities of Press-in method.

Footing Structure

Implanted Structure
PlanPlanPressed-in
Pile Wall

Cross Section

Capping

Cross Section

Strut
Waling

Temporary
Retaining Wall

RevolutioninStructures

Integration
with the Earth

Main Structure
Foundation (Footing)
Excavation Work Area

13

Structural Part and Foundation Part

Eco Underpass Method

The GRB System
The GRB System is named from “Giken Reaction Base” and means a systematic method which is based onsuperiorities of Press-in principle. Under this system, the Press-in machine, the Clamp Crane and the Pile Runnerare operated systematically on the top of installed sheet piles. There are 5 major characteristics, ① All machines
hold those installed pile tops during operation so that it is safe from any collapse, ② No temporary work for operation
stages, ③ No restriction or limitation on working condition such as slope, above water and urban area. ④ It is also
applicable for removal work. ⑤ The minimum required working width is the same as the width of the machine, sothat it is applicable in a narrow working space. Hence the GRB System contains
all necessary functions of piling activities with Press-in principles. The GRB
System promises the Five Construction Principles in order to change
conventional piling methods under the name of Construction Revolution.

The GRB System
Clamp Crane
Pile RunnerSilent Piler

Power Unit

Application forRoad Widening

14

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Ver 1.1EN03 / 27 Feb 2014